SANAL K SANTHOSH
Summary
Experienced Instrumentation Maintenance Team Lead with over 6 years of hands-on experience in operations, calibration, assembly, maintenance, and production of various instrumentation and control systems. Demonstrated ability to optimize system performance and reduce downtime effectively.
Overview
8
8
years of professional experience
Work History
Instrumentation Team Lead
Global Fluorine Chemical Factory LLC
01.2023 - Current
- Lead a team of technicians in installation, calibration, and maintenance of instrumentation systems across the plant.
- Supervised loop checking, signal testing, and commissioning during shutdown and start-up operations.
- Developed and implemented preventive maintenance schedules, reducing breakdowns.
- Coordinated with vendors for FAT/SAT and ensured compliance with IEC and ISA standards.
- Supported integration and troubleshooting of DCS (yokogawa) and PLC (Siemens) systems.
- Maintained accurate documentation of instrument calibration records, reports, and as-built drawings.
Quality Controller
Hykon India Limited
03.2020 - 10.2021
- Company Overview: Kerala, India
- Conducted in-process and final quality inspections of e-auto battery units, ensuring compliance with ISO standards and company specifications.
- Performed routine testing of battery performance parameters including voltage, charge/discharge cycles, load capacity, and thermal characteristics.
- Monitored assembly line processes to detect and correct quality deviations in real-time, reducing product rejection rate.
- Collaborated with production and R&D teams to resolve recurring quality issues and implement process improvements.
- Maintained detailed inspection reports, quality logs, and documentation for audits and traceability.
- Ensured adherence to safety protocols and standard operating procedures (SOPs) across the production floor.
- Kerala, India
- Conducted quality inspections to ensure compliance with industry standards and specifications.
Quality Analyzer
Ausec Technology
03.2019 - 02.2020
- Company Overview: Kerala, India
- Conducted quality analysis of Printed Circuit Boards (PCB) and Battery Management Systems (BMS) at various production stages to ensure compliance with industry standards and design specifications.
- Performed functional testing, visual inspection, and component verification using multimeters, oscilloscopes, and automated test equipment (ATE).
- Identified and documented defects such as soldering issues, component misalignment, and signal irregularities, and coordinated with the production team for corrective actions.
- Validated firmware updates and tested communication protocols (CAN, UART) in BMS units for performance and reliability.
- Assisted in root cause analysis and implementation of corrective/preventive actions (CAPA) to improve product quality.
- Maintained QA/QC records, inspection reports, and contributed to internal audit processes as per ISO 9001 standards.
- Supported the integration of quality control systems in alignment with lean manufacturing and continuous improvement initiatives.
- Kerala, India
Instrumentation Technician - Maintenance & Operations
Tamil Nadu Petro Products Ltd.
08.2017 - 02.2019
- Company Overview: Chennai, India
- Performed routine and preventive maintenance of field instruments including pressure, temperature, flow, and level transmitters in petrochemical processing units.
- Conducted calibration, loop checking, and functional testing of control valves, switches, and transmitters using HART communicators and standard calibrators.
- Supported DCS (Yokogawa) and PLC (Allen Bradley) operations by troubleshooting I/O modules, signal routing, and field-device interface issues.
- Collaborated with engineering teams to implement process improvements in instrumentation workflows.
- Responded to emergency breakdowns, performed root cause analysis, and restored equipment functionality with minimal downtime.
- Assisted in shutdown and turnaround activities, ensuring timely execution of instrumentation maintenance schedules as per company standards.
- Maintained and updated instrumentation maintenance logs, calibration records, and compliance documentation in line with ISO and safety regulations.
- Ensured all work adhered to plant safety practices, including PTW (Permit to Work), LOTO, and HSE procedures.
- Chennai, India
- Diagnosed and resolved equipment malfunctions, minimizing downtime and enhancing operational efficiency.
Education
B.Tech. - ELECTRONICS AND INSTRUMENTATION ENGINEERING
Jawaharlal Nehru Technological University
Hyderabad05-2017
Skills
- Field calibration proficiency
- System loop testing and commissioning
- SCADA system management
- Instrument Installation & Wiring
- Control Valve Testing & Tuning
- Technical instrumentation drawings
- Proficient in HART communication
- Troubleshooting Analog/Digital Signals
- Vibration Monitoring Systems
- Panel Testing & Precommissioning
- Team Supervision & Training
- Shift Planning & Resource Allocation
- Maintenance Planning & Scheduling
- Project Coordination
- Vendor & Contractor Management
- Documentation & Reporting
- Permit to Work (PTW) System
- Confined Space Entry Procedures
- Hazardous Area Classification
- Risk Assessment & Safety Compliance
- ISO 9001 / 14001 / 45001 Understanding
- AutoCAD
- MS Excel
Languages
English
Hindi
Malayalam
Tamil
Personal Information
- Driving License: Valid UAE Driving License
Awards
- Best Maintenance Team Award - for reduced downtime or improved reliability.
- Safety Excellence Award - for following HSE protocols during instrumentation work.
- Best Shutdown Execution Award - for lead and supporting a successful plant shutdown.
Timeline
Instrumentation Team Lead
Global Fluorine Chemical Factory LLC
01.2023 - Current
Quality Controller
Hykon India Limited
03.2020 - 10.2021
Quality Analyzer
Ausec Technology
03.2019 - 02.2020
Instrumentation Technician - Maintenance & Operations
Tamil Nadu Petro Products Ltd.
08.2017 - 02.2019
B.Tech. - ELECTRONICS AND INSTRUMENTATION ENGINEERING
Jawaharlal Nehru Technological University
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